High-Power, Low-Force (HPLF) Connectors - DCX

DCX-C HOL Enterprises,
Inc.
CORPORATE ADDRESS
12831 SOUTH FIGUEROA STREET
LOS ANGELES, CA 90061-1157
USA
310.516.1692 (TEL)
310.516.1693 (FAX)
WWW.DCXCHOL.COM
High-Power, Low-Force (HPLF) Connectors
DCX-CHOL new family of high-power, low-force (HPLF) connectors utilizes MIL-C-38999,
series III shell styles, and proprietary layouts to lend a new dimension to reliable highpower transmission for many applications. Patented HPLF power contacts can now be
installed in slightly modified versions of MIL-C-38999, series III connectors, or other
connector styles as required.
Contacts that accommodate wire sizes from 20 AWG to 4/0 can now be incorporated
into these reliable connectors. The socket contact design incorporates independent
gold plated copper wire conductors that are typically woven with a Kevlar fiber. This
flexible fiber is under tension to provide a low normal force between the socket and it’s
mating pin contact. The resultant is a contact that can provide hundreds of contact
points.
DCX DIVISION
ELECSYS DIVISION
MASTERITE DIVISION
NEW VAC DIVISION
TELETRONIC DIVISION
9330 DE SOTO AVE.
225 ENTERPRISE DR.
12831 S. FIGUEROA ST.
9330 DE SOTO AVE.
12831 S. FIGUEROA ST.
CHATSWORTH, CA 91311
PEKIN, IL 61554
LOS ANGELES, CA 90061
CHATSWORTH, CA 91311
LOS ANGELES, CA 90061
DCX-C HOL Enterprises,
Inc.
CORPORATE ADDRESS
12831 SOUTH FIGUEROA STREET
LOS ANGELES, CA 90061-1157
USA
310.516.1692 (TEL)
310.516.1693 (FAX)
WWW.DCXCHOL.COM
This design dramatically reduces the electrical resistance across a pair of mated
contacts. In fact, the use of high conductivity copper wires instead of conventional
spring copper alloys enhances this performance. Due to this improvement, the current
carrying capacity of the contacts is significantly enhanced.
DCX DIVISION
ELECSYS DIVISION
MASTERITE DIVISION
NEW VAC DIVISION
TELETRONIC DIVISION
9330 DE SOTO AVE.
225 ENTERPRISE DR.
12831 S. FIGUEROA ST.
9330 DE SOTO AVE.
12831 S. FIGUEROA ST.
CHATSWORTH, CA 91311
PEKIN, IL 61554
LOS ANGELES, CA 90061
CHATSWORTH, CA 91311
LOS ANGELES, CA 90061
DCX-C HOL Enterprises,
Inc.
CORPORATE ADDRESS
12831 SOUTH FIGUEROA STREET
LOS ANGELES, CA 90061-1157
USA
310.516.1692 (TEL)
310.516.1693 (FAX)
WWW.DCXCHOL.COM
As can be seen from the chart above, a wired M39029 type contact (as used on standard
MIL-C-38999, series III connectors) is considerably de-rated with respect to the
equivalent gauge wire. A size 16 contact is rated at 13 amps (source: Amphenol
connectors) while the equivalent size wire (16 AWG) is rated at 32 amps (source:
Standard Wire and Cable). With the DCX-CHOL HPLF contacts, the 32 amps rating can
be maintained. Furthermore, we should be able to use a size 20 contact interface. This
dramatically increases the current rating from a typical size 20 contact (rated at 7.5
amps) to a 16 AWG wire (rated at 32 amps). This represents a gain of more than 4 times
the current carrying capacity for this example. This is still well below the current rating
of the size 20 HPLF contact of 70 amps, as shown on the chart above, for a busbar
application.
The potential contact size reduction (with respect to the wire) on these connectors is as
follows:
M39029 contacts / wire AWG
HPLF contacts
16
20
12
16
8
12
4
8
1/0
4
4/0
1/0
The smaller size contact would produce a smaller connector interface or more contacts
could be accommodated on the same interface. This would result on a lower weight
connector, approximately 1/3 the weight of a standard connector.
DCX DIVISION
ELECSYS DIVISION
MASTERITE DIVISION
NEW VAC DIVISION
TELETRONIC DIVISION
9330 DE SOTO AVE.
225 ENTERPRISE DR.
12831 S. FIGUEROA ST.
9330 DE SOTO AVE.
12831 S. FIGUEROA ST.
CHATSWORTH, CA 91311
PEKIN, IL 61554
LOS ANGELES, CA 90061
CHATSWORTH, CA 91311
LOS ANGELES, CA 90061
DCX-C HOL Enterprises,
Inc.
CORPORATE ADDRESS
12831 SOUTH FIGUEROA STREET
LOS ANGELES, CA 90061-1157
USA
310.516.1692 (TEL)
310.516.1693 (FAX)
WWW.DCXCHOL.COM
Another advantage of this design is the low engagement forces achieved due to the
reduced contact normal forces. As a result, insertion and withdrawal forces, as well as
contact wear are minimized. The contacts maintain a highly redundant contact surface,
as well as a wipe across the mating surfaces to clear debris and to break oxide layers.
With these HPLF connectors, DCX-CHOL provides a full set of cable assemblies and
other turn-key options. Hi-power wired or cabled terminations are overmolded to
provide the proper protection for strain relief and sealed environments. Straight,
angled and 90 degrees exit terminations with low profile are available. Other options
and performance requirements can be incorporated and tested, as required by the
program.
DCX DIVISION
ELECSYS DIVISION
MASTERITE DIVISION
NEW VAC DIVISION
TELETRONIC DIVISION
9330 DE SOTO AVE.
225 ENTERPRISE DR.
12831 S. FIGUEROA ST.
9330 DE SOTO AVE.
12831 S. FIGUEROA ST.
CHATSWORTH, CA 91311
PEKIN, IL 61554
LOS ANGELES, CA 90061
CHATSWORTH, CA 91311
LOS ANGELES, CA 90061